RU2749791C2 - Filter materials, filter material packages and filter elements - Google Patents

Abstract

FIELD: filter materials.SUBSTANCE: invention relates to filter materials, filter media packages, filter elements, air cleaners and methods for the manufacture and use of filter materials, filter material packages, filter elements and air cleaners. In particular, embodiments of the present invention relate to zigzag filter materials, filter material packages, and filter elements. The air filtration material package contains a single-sided material containing the first set of riffles and the second set of riffles. The first and second sets of riffles are arranged in a parallel flow configuration. The first and second sets of riffles are characterized by differences in the shape of the riffles, the size of the riffles, the height of the riffles, the width of the riffles, the cross-sectional area of the riffles, or the filter material. The first set of riffles is located in the first set of layers of corrugated material in the material package, the second set of riffles is located in the second set of layers of corrugated material in the material package.EFFECT: improving the filter performance, reducing the pressure loss on the element, increasing the ability to capture solid particles.19 cl, 30 dwg

Description

This application is filed as a PCT international patent application on December 12, 2017, on behalf of Donaldson Company, Inc., a US national corporation, applicant for all countries, and Daniel E. Adamek, a US citizen; Scott M. Brown, US citizen; and Mark A. Sala, US citizen; the inventors for all designated countries, and claims priority from US Provisional Patent Application No. 62/433145, filed December 12, 2016, the entire contents of which are incorporated herein by reference.

Technology area

[0001] Embodiments of the invention relate to filter media, filter media packages, filter elements, air cleaners, and methods for making and use of filter media, filter media packages, filter elements, and air cleaners. In particular, embodiments of the present invention relate to zigzag filter media, filter media packages, and filter elements.

Background of the invention

[0002] Zigzag filter media, such as those described in US Pat. No. 7,959,702 to Rocklitz, contain multiple layers of material. Each layer contains a corrugated sheet, a face sheet, and a plurality of corrugations extending from the first face to the second face of the filter media stack. The first part of the plurality of corrugations is closed for passage of unfiltered air into the first part of the plurality of corrugations, and the second part of the plurality of corrugations is closed for the exit of unfiltered air from the second part of the plurality of corrugations. Air passing into the riffle through one face of the material stack passes through the filter media before exiting the riffle on the other face of the material stack.

[0003] While zigzag materials have many advantages, there remains a need to improve the performance of filters, including filter media, filter media packages, and filter elements, with reduced element pressure loss and / or improved particulate trapping.

The essence of the invention

[0004] The present invention relates to filter media, filter media packages, filter elements and air cleaners with two or more different material configurations, as well as methods of making and using these materials, media bags, filter elements and air cleaners. Different configurations of materials can represent, for example, different geometries of the grooves in the zigzag filter material. The use of two or more filter media configurations allows performance enhancements such as reduced pressure loss and / or increased collection capacity compared to using a single media configuration.

[0005] In exemplary implementations, sections of two different materials are combined into a single filter element, the sections of the two materials having different pressure loss and trapping properties. The difference in pressure loss and trapping properties between material sections is generally less than the typical variation seen in filter elements due to fabrication variances, so typically, the reported difference for a particular measurable and variable parameter will be at least 5% for a given measured and variable, and more typically at least 10%.

[0006] In one exemplary configuration, the first material section has less initial pressure loss than the second material section, while the second material section has greater dust-collecting capacity than the first material section. In some structures, combining sections of the two specified materials results in an element with better performance than could be achieved with a stack of materials made from only one of the specified materials separately, and better than those that could can be achieved by simply averaging the performance characteristics of the sections of each material. Thus, the hybrid filter element can (for example) exhibit reduced initial pressure loss as well as increased collection capacity relative to stacks of materials made from only one or the other material.

[0007] For example, the height of the corrugation may change, and then individual layers of material have variable heights, several layers of material have different heights, or sections of materials having a larger size have different heights.

[0008] The flow through the various specified layers and sections of materials, as a rule, is a parallel flow. As used herein, the term "parallel" refers to a structure in which the flow of fluid to be filtered forks into first and second sets of corrugations and then typically converges again. As such, the term "parallel" does not require the riffles themselves to be arranged in a geometrically parallel configuration (although they are often so), but rather that the sets of riffles are characterized by parallel flow relative to one another. Thus, the term "parallel flow" is used as opposed to "sequential" flow (where in a sequential flow, the stream goes from one set of riffles to a second set of riffles).

[0009] The structures made in accordance with the disclosure of the present application provide the opportunity to improve both in terms of pressure loss and dust-collecting ability with respect to filter media packs and filter elements made of the same type of material. In addition, in some implementations it is possible to add additional material to a predetermined volume without significantly increasing the initial pressure loss. As such, a structure of materials can be created that has a relatively small initial pressure loss and, at the same time, still has a relatively high dust-holding capacity. This improvement can be obtained by combining a first material having a low initial pressure loss (but also a low dedusting capacity) with a second material having a higher initial pressure loss (and a higher dedusting capacity). The resulting composite material, in some embodiments, exhibits a similar initial pressure loss to the first material, but at the dust-holding capacity of the second material.

[0010] The advantages of hybrid material structures can also be used to produce more materials in a given volume, as well as trap more dust in a given surface area of materials. Thus, improved performance can be obtained with fewer materials.

[0011] In exemplary structures, the stack of the first material may comprise, for example, about 10, 20, 30, 40, 50, 60, 70, 80, or 90% of the stack of materials (by volume of the stack); and the stack of second material may comprise, for example, about 10, 20, 30, 40, 50, 60, 70, 80, or 90% of the stack of materials (by volume of the stack). In the framework of this application, "package volume" means the total volume occupied by a package of materials when measuring its area within the perimeter of the package. Thus, the volume of the stack may include the material itself, as well as an upstream free volume that can trap dust, and a volume downstream through which filtered air exits the stack of materials. Alternatively, the first set of grooves makes up 20-40% of the package volume, and the second set of grooves makes up 60-80% of the package volume. In other implementations, the first set of corrugations is 40-60% of the package volume, and the second set of corrugations is 60-40% of the package volume. In yet another implementation, the first plurality of corrugations constitutes 60-90% of the entry surface of the stack of materials, and the second plurality of corrugations constitutes 40-10% of the volume of the stack.

[0012] In these exemplary structures, the stack of the first material may comprise, for example, about 10, 20, 30, 40, 50, 60, 70, 80, or 90% of the stack of materials (by volume of the stack); and the second material may constitute, for example, about 10, 20, 30, 40, 50, 60, 70, 80, or 90% of the stack of materials (by volume of the stack). As used herein, "stack surface area" means the total surface area of the materials in each stack of materials when the stack of materials is disassembled and the materials are stretched. Alternatively, the first plurality of corrugations is 20-40% of the surface area of the material, and the second plurality of corrugations is 60 -80% of the surface area of the material. In other implementations, the first plurality of corrugations constitutes 40-60% of the material inlet surface area, and the second plurality of corrugations constitutes 60-40% of the surface area of the stack of materials. In yet another implementation, the first plurality of corrugations constitutes 60-90% of the surface area of the material, and the second plurality of corrugations constitutes 40-10% of the surface area of the materials. Packages of materials can also be characterized by the proportion of the inlet surface occupied by a particular type of material. In some implementations, the package of the first material (containing the first plurality of corrugations) constitutes 10-90% of the entrance surface of the package of materials, for example, 10, 20, 30, 40, 50, 60, 70, 80, or 90% of the entrance surface of the package of materials; and the stack of the second material (containing the second plurality of corrugations) constitutes 90-10% of the entrance surface of the stack of materials, for example, 90, 80, 70, 60, 50, 40, 30, 20, or 10% of the entrance surface of the stack of materials. Alternatively, the first plurality of corrugations constitutes 20-40% of the inlet surface of the stack of materials, and the second plurality of corrugations constitutes 60-80% of the inlet surface of the stack of materials. In other implementations, the first plurality of corrugations constitutes 40-60% of the inlet surface of the stack of materials, and the second plurality of corrugations constitutes 60-40% of the inlet surface of the stack of materials. In yet another implementation, the first plurality of corrugations constitutes 60-90% of the input surface of the stack of materials, and the second plurality of corrugations constitutes 40-10% of the input surface of the stack of materials.

[0013] In another embodiment, the filter media stack comprises a third plurality of corrugations disposed in a parallel flow configuration with the first and second plurality of corrugations; wherein the first, second and third sets of corrugations are characterized by regularly recurring differences in corrugation shape, corrugation size, corrugation height, corrugation width, corrugation cross-sectional area, or filter material. Optionally, each of the first, second and third plurality of grooves is disposed in a separate plurality of layers. It will be appreciated that in some implementations more than three sets of corrugations are disposed in a parallel flow configuration, each of the sets of corrugations being characterized by differences in corrugation shape, corrugation size, corrugation height, corrugation width, corrugation cross-sectional area, or filter media. These differences in properties are often repeated and are often repeated regularly.

[0014] In an exemplary structure comprising three types of riffles, the first, second, and third riffles may be selected such that the first plurality of riffles represent 20-50% of the stack of materials, such as 20, 30, 40, or 50% of the volume of the stack of materials; the second plurality of corrugations constitutes 20-50% of the volume of the package of materials, for example, 20, 30, 40 or 50% of the volume of the package of materials; and the third set of corrugations constitutes 20-50% of the volume of the package of materials, for example, 20, 30, 40 or 50% of the volume of the package of materials.

[0015] In an exemplary structure comprising three types of riffles, the first, second, and third riffles may be selected such that the first plurality of riffles represent 20-50% of the surface area of the materials of the stack of materials, such as 20, 30, 40, or 50% of the surface area filter media package materials; the second plurality of corrugations constitutes 20-50% of the surface area of the materials of the package of materials, for example, 20, 30, 40, or 50% of the surface area of the materials of the package of materials; and the third plurality of corrugations constitutes 20-50% of the surface area of the materials of the package of materials, for example, 20, 30, 40, or 50% of the surface area of the materials of the package of materials.

[0016] In an exemplary structure comprising three types of riffles, the first, second, and third riffles may be selected such that the first plurality of riffles represent 20-50% of the entry surface of the stack of materials, such as 20, 30, 40, or 50% of the entry surface of the stack. materials; the second plurality of corrugations constitutes 20-50% of the inlet surface of the stack of materials, for example 20, 30, 40, or 50% of the inlet surface of the stack of materials; and the third plurality of corrugations constitutes 20-50% of the inlet surface of the stack of materials, for example 20, 30, 40, or 50% of the inlet surface of the stack of materials.

[0017] An exemplary air filtration stack contains a plurality of layers of corrugated zigzag materials. In some structures, each layer of material contains a face sheet and a corrugated sheet. Each corrugated sheet contains a plurality of corrugations characterized by regularly recurring differences in corrugation shape, corrugation size, corrugation height, corrugation width, corrugated cross-sectional area, or filter material. These sets of riffles are arranged in a parallel flow pattern. The face sheet can be made, for example, of the same material as the material forming the corrugated sheet, or it can be made of a different material. The face sheet is usually not corrugated, however, it may be corrugated in some structures. The face sheet may be filtering properties, or it may be a non-filtering material without filtering properties (eg, a cushioning material). In addition, the face sheet may cover the entire corrugated sheet or only part of it. The face sheet can be solid or segmented so that separate face sheet segments are placed opposite each face sheet.

[0018] Various types of materials in a plurality of corrugations are arranged in a parallel flow configuration with respect to each other. As noted above, in the context of this application, the term "parallel" refers to a structure in which the flow of fluid to be filtered forks into first and second sets of corrugations and then usually converges again. As such, the term "parallel" does not require the riffles themselves to be arranged in a geometrically parallel configuration (although they are often so), however, the plurality of riffles as a whole are rather in a parallel flow configuration relative to one another. Thus, the term "parallel flow" is used as opposed to "sequential" flow, in which the flow exits from one set of riffles into a second set of riffles. As will be appreciated, in some structures, such as a coiled structure, fluid flow may occur between adjacent sections of filter media.

[0019] These materials can be located in a stack of materials in a variety of structures containing alternating one-sided layers (for example, structure A / B / C / A / B / C ..., where A, B and C are different types of grooves, and " / "Denotes individual layers. Thus, A / B / C / A / B / C ... refers to corrugated materials with a first corrugated layer having an A configuration, followed by a second corrugated layer having a B configuration and a third corrugated layer, configuration C. This order is repeated in the fourth, fifth and sixth layers in the A / B / C / A / B / C arrangement. To create a complete package of materials, the A / B / C arrangement can be repeated many times.

[0020] The use of the terms "A", "B" and "C" for grooves is intended to represent materials with different properties. For example, Type A riffles may be higher than Type B or Type C riffles; or Type B riffles may be higher than Type A or Type C riffles; or Type A riffles may be formed of a material with greater efficiency and / or permeability than Type B or C riffles.

[0021] It should also be understood that the material can be located in structures where layers of similar grooves are grouped together, for example in a stack of materials having the structure A / A / A / A / B / B / B / C / C / C ... This structure has four corrugated A layers, three corrugated B layers and three corrugated C layers. The A, B and C corrugated layers are grouped together. Different zones of materials containing different types of riffles can directly contact one another, for example, being located in a stacked or folded configuration. In addition, they are arranged in such a way that the different areas of the materials are separated by a separator or other component.

[0022] It should also be understood that there may be more than three or four layers of similar corrugations grouped with each other depending on the size of the corrugations, the size of the stack of materials, etc. A stack of materials can be created with as many layers of each material as (for example) ten, twenty, thirty, or forty grouped layers of corrugation A; or ten, twenty, thirty, or forty grouped layers of ribbed B, etc.

[0023] In some structures, the riffles may vary in a repetitive manner within a layer as well as between layers. For example, a package of materials containing the structure ABC ... / DEF ... / ABC ... / DEF ... / ABC ... / DEF ... contains layers with repeating ribs A, ribs B and ribs C, which alternate with layers containing ribs D, ribs E and ribs F. Other examples without limitation include a package of materials with the structure AB ... / CDEF ... / AB ... / CDEF; package of materials with structure А ... / BCD ... / А ... / BCD ....

[0024] Using more than one flute configuration in a given filter media package or air cleaner can provide various benefits, including having less initial limitation on one flute configuration and the dedusting capacity of a second flute configuration. Thus, elements formed from composite materials can be superior to elements formed from corrugations of only one configuration. Thus, combining flutes with different types and types of geometries provides advantages in one or more of the following: cost, loss of initial pressure, capturing ability, or other aspects of filter performance.

[0025] In some structures, the relative position of materials is determined by the desired properties of the element. For example, to reduce the initial restriction, material with greater permeability can be located in those areas of the filter element that have the highest flow rate in the head section due to the configuration of the air cleaner in which it is located. In other embodiments, to increase the initial efficiency of the filter element, the most efficient material is located in the areas with the highest flow rate in the frontal section.

[0026] This summary is an overview of some of the ideas of this application and should not be construed as an exclusive or exhaustive interpretation of the subject of the invention. Further details can be found in the detailed description and the appended claims. Other aspects will become apparent to those skilled in the art upon reading and understanding the following detailed description and considering the graphic materials that form part of it, each of which should not be construed in a limiting sense. The scope of the present invention is defined by the appended claims and their legal equivalents.

Brief description of the figures

[0027] Aspects of the invention may be more fully understood in conjunction with the following figures, in which:

[0028] FIG. 1 is a perspective view of an exemplary filter element constructed in accordance with an exemplary embodiment.

[0029] FIG. 2A is an enlarged schematic cross-sectional view of a section of filter media.

[0030] FIG. 2B is a partial enlarged view of a sheet of corrugated material with top and bottom face sheets.

[0031] FIG. 3 is a schematic top view of an exemplary filter media package showing a folded configuration with two types of filter media.

[0032] FIG. 4 is a schematic top view of an exemplary filter media package showing a folded configuration with three types of filter media.

[0033] FIG. 5 is a schematic top view of an exemplary filter media stack showing a stacked configuration of filter media.

[0034] FIG. 6 is a schematic top view of an exemplary filter media stack showing a stacked configuration of filter media.

[0035] FIG. 7 is a schematic top view of an exemplary filter media stack showing a stacked configuration of filter media.

[0036] FIG. 8 is a schematic top view of an exemplary filter media package showing a stacked configuration with three types of filter media.

[0037] FIG. 9 is a schematic top view of an exemplary filter media package showing a stacked configuration with two types of filter media.

[0038] FIG. 10 is a schematic top view of an exemplary filter media stack showing a stacked configuration with two types of filter media.

[0039] FIG. 11 is a schematic top view of an exemplary filter media stack showing a stacked configuration with two types of filter media.

[0040] FIG. 12 is a schematic top view of an exemplary filter media stack showing a stacked configuration with two types of filter media.

[0041] FIG. 13 is a schematic top view of an exemplary filter media stack showing a stacked configuration with two types of filter media.

[0042] FIG. 14 is a schematic top view of an exemplary filter media package showing a stacked configuration with three types of filter media.

[0043] FIG. 15 is a schematic top view of an exemplary filter media package showing a folded configuration with two types of filter media.

[0044] FIG. 16 is a schematic top view of an exemplary filter media package showing a folded configuration with three types of filter media.

[0045] FIG. 17 is a schematic top view of an exemplary filter media package showing a stacked configuration with three types of filter media.

[0046] FIG. 18 is a schematic top view of an exemplary filter media stack showing a stacked configuration with two types of filter media.

[0047] FIG. 19 is a schematic top view of an exemplary filter media stack showing a stacked configuration with two types of filter media.

[0048] FIG. 20 is a schematic top view of an exemplary filter media package showing a stacked configuration with two types of filter media.

[0049] FIG. 21 is a schematic top view of an exemplary filter media package showing a stacked configuration with two types of filter media.

[0050] FIG. 22 is a schematic top view of an exemplary filter media stack showing a stacked configuration with two types of filter media.

[0051] FIG. 23 is a schematic top view of an exemplary filter media package showing a stacked configuration with three types of filter media.

[0052] FIG. 24A is a schematic top view of an exemplary filter media stack showing a rolled configuration with two types of filter media.

[0053] FIG. 24B is a schematic top view of an exemplary filter media stack showing a folded configuration with two types of filter media.

[0054] FIG. 25A is a schematic top view of an exemplary filter media stack showing a rolled configuration with three types of filter media.

[0055] FIG. 25B is a schematic top view of an exemplary filter media package showing a folded configuration with three types of filter media.

[0056] FIG. 26A is a schematic top view of an exemplary filter media stack showing a rolled configuration with two types of filter media.

[0057] FIG. 26B is a schematic top view of an exemplary filter media stack showing a folded configuration with two types of filter media.

[0058] FIG. 27 shows the results of determining the performance characteristics obtained in a comparative test of filter elements with different types of materials.

[0059] FIG. 28A and 28B show performance test results, including dust loading and pressure loss, for various material structures.

[0060] FIG. 29A and 29B show performance test results, including dust loading and pressure loss, for various material structures.

[0061] FIG. 30A and 30B show performance test results, including dust loading and pressure loss, for various material structures.

[0062] Although the embodiments may have various modifications and alternative forms, its features have been illustrated in the examples and in the drawings and will be described in detail. However, it should be understood that the scope of the present invention is not limited to the described embodiments. On the contrary, the invention is intended to cover modifications, equivalents and alternatives falling within the spirit and scope of the present invention.

Detailed description

[0063] The present invention, in an exemplary embodiment, is directed to an air filtration stack comprising a plurality of corrugated layers, each layer comprising a first plurality of corrugations and a second plurality of corrugations, the first and second pluralities of corrugations disposed in a parallel flow configuration; wherein the first and second pluralities of corrugations are characterized by differences in corrugation shape, corrugation size, corrugation height, corrugation width, corrugation cross-sectional area, or filter material.

[0064] These pluralities of ripples are arranged in a parallel flow configuration. As noted above, within this context, the term "parallel" refers to a structure in which the flow of fluid to be filtered forks into first and second sets of riffles and then typically converges again. As such, the term "parallel" does not require the riffles themselves to be arranged in a geometrically parallel configuration (although they are often so), but rather that the sets of riffles are characterized by parallel flow relative to one another. Thus, the term "parallel flow" is used as opposed to "sequential" flow (where in a sequential flow, the stream goes from one set of riffles to a second set of riffles).

[0065] In some implementations, the filter media stack may be designed such that the first and second plurality of corrugations are positioned together within at least one layer of corrugated material. In other implementations, the first plurality of corrugated material is located in the first plurality of layers and the second plurality of corrugated material is located in the second plurality of corrugated material layers. These two structures can also be combined so that the individual layers contain repeated differences between the grooves, and different layers are combined.

[0066] In exemplary implementations, packs of two different materials are combined into a single filter element, the packs of the two materials having different pressure loss and trapping properties. In one example, the stack of the first material has a lower initial pressure loss than the stack of the second material, while the stack of the second material has a greater dust collection capacity than the stack of the first material. In some structures, the combination of these two materials results in an element that either has better performance than could be achieved with either of the materials alone, or that could be achieved by simply averaging the performance of each stack of materials. Thus, the hybrid filter element can (for example) exhibit a reduced initial pressure drop, but also an increased collection capacity.

[0067] In exemplary structures, the stack of the first material may comprise, for example, about 20, 30, 40, or 50% of the stack of materials (by volume of the stack); and the stack of second material may be, for example, about 20, 30, 40, or 50% of the stack of materials (by volume of the stack). In the framework of this application, "package volume" means the total volume occupied by a package of materials when measuring its area within the perimeter of the package. Thus, the volume of the bag can include the materials themselves, as well as the free volume that can trap dust.

[0068] In such exemplary structures, the stack of the first material may be, for example, about 20, 30, 40, or 50% of the stack of materials (in terms of surface area of the materials); and the stack of the second material can be, for example, about 20, 30, 40, or 50% of the stack of materials (in terms of surface area of the materials). As used herein, “stack surface area” means the total surface area of the materials in each stack of materials when the stack of materials is disassembled and the materials are stretched.

[0069] In some implementations, the first plurality of corrugations is 10-90% of the entry surface of the stack of materials, and the second plurality of corrugations is 90-10%

input surface of the package of materials. Alternatively, the first plurality of corrugations constitutes 20-40% of the inlet surface of the stack of materials, and the second plurality of corrugations constitutes 60-80% of the inlet surface of the stack of materials. In other implementations, the first plurality of corrugations constitutes 40-60% of the inlet surface of the stack of materials, and the second plurality of corrugations constitutes 60-40% of the inlet surface of the stack of materials. In yet another implementation, the first plurality of corrugations constitutes 60-90% of the input surface of the stack of materials, and the second plurality of corrugations constitutes 40-10% of the input surface of the stack of materials.

[0070] In another embodiment, the filter media stack comprises a third plurality of corrugations disposed in a parallel flow configuration with the first and second plurality of corrugations; wherein the first, second and third sets of corrugations are characterized by regularly recurring differences in corrugation shape, corrugation size, corrugation height, corrugation width, corrugation cross-sectional area, or filter material. Optionally, each of the first, second and third plurality of grooves is disposed in a separate plurality of layers. It will be appreciated that in some implementations, more than three sets of corrugations are disposed in a parallel flow configuration, each of the sets of corrugations characterized by regularly recurring differences in corrugation shape, corrugation size, corrugation height, corrugation width, corrugation cross-sectional area, or filter media.

[0071] In an exemplary structure comprising three types of riffles, the first, second, and third riffles may be selected such that the first plurality of grooves constitute 30-50% of the entry surface of the stack of materials; the second set of corrugations makes up 20-40% of the entrance surface of the package of materials; and the third set of corrugations constitutes 20-40% of the entry surface of the package of materials.

[0072] In another exemplary structure comprising three types of riffles, the first, second, and third riffles may be selected such that the first plurality of riffles constitute 50-70% of the entry surface of the stack of materials; the second plurality of corrugations constitutes 10-30% of the entrance surface of the package of materials; and the third plurality of corrugations constitutes 10-30% of the entry surface of the stack of materials.

[0073] In some implementations, a plurality of layers of double-sided corrugated material are located in a rolled configuration, while in other implementations, double-sided corrugated materials are located in a stacked configuration.

[0074] In some configurations, the first and second plurality of double-sided corrugations are disposed in a mixed configuration with one or more layers of the first plurality of double-sided corrugations alternating with one or more layers of the second plurality of double-sided corrugations. In exemplary implementations with one-sided materials of at least three kinds, the first and second plurality of layers of one-sided materials are arranged in a mixed configuration with one or more layers of the first plurality of one-sided materials, alternating with one or more layers of the second plurality of one-sided materials and one or more layers of the third plurality of one-sided materials. materials. In addition, if three types of materials are used, the first, second and third plurality of single-sided materials may be arranged in a mixed configuration with one or more layers of the first plurality of one-sided materials alternating with one or more layers of the second plurality of one-sided materials and one or more layers of the third. many one-sided materials. In some implementations more than three types of filter media are used, and these different types of media can be combined, either in a mixed or grouped manner, in which different types of media are brought together without mixing between the types of media. Alternatively, materials can be grouped into small size groups and then mixed so that there are five layers of one material and three layers of another material.

[0075] Further aspects of filter media, filter media packages, and filter elements will be defined below with reference to the drawings.

[0076] First of all, with regard to FIG. 1 is a perspective view of an exemplary filter element 10. An exemplary filter element 10 comprises an inlet 12, an outlet 14 on the opposite side of the inlet 12 of the element 10, and a coiled zigzag material 20 within the element 10. A seal 30 surrounding the inlet 12 is shown and a carrier is shown. frame 40. It should also be understood that the filter element may have a flow direction opposite to that shown in FIG. 1, and then the inlet 12 and the outlet 14 are interchanged.

[0077] FIG. 2A is an enlarged schematic cross-sectional view of a section of one-sided filter media 200 suitable for use in filter media bags and filter elements disclosed herein. The one-sided material 200 comprises a corrugated sheet 210 along with an upper facing sheet 220 and a lower facing sheet 230. The corrugated sheet 210 contains a plurality of corrugations 250. The flow of fluid to be filtered, such as air for an internal combustion engine, enters the corrugations 250 along the flow path 260 , and then moves along the grooves until it exits through the filter media out of the various grooves along the flow path 270. This fluid flow through bundles of corrugated materials is described, for example, in US Pat. No. 799,702 issued to Rocklitz, which is hereby incorporated by reference in its entirety.

[0078] FIG. 2B is an enlarged front view of a corrugated sheet with corrugated sheet 280, topsheet 282, and facing 284 constructed and positioned in accordance with an embodiment of the invention, showing the dimensions of exemplary corrugations. The corrugated sheet 280 comprises corrugations 281. The corrugations 281 in the illustrated embodiment have a width A, measured from the first vertex to the adjacent vertex. In exemplary embodiments, the width A is 0.75 to 0.125 inches, optionally 0.5 to 0.25 inches, and optionally 0.45 to 0.3 inches. The riffles 281 also have a height B measured from adjacent vertices of the same size. The riffles 281 have an area between the corrugated sheet 281 and the face sheet 282, measured perpendicular to the length of the riffle. This area can vary along the length of the riffle as the height, width, or shape of the riffle changes along the length, for example, when the riffle narrows.

[0079] FIG. 3 is a schematic top view of an exemplary filter media stack 300 for use in a filter element. The filter media stack 300 contains two types of filter media: a first material 310 and a second material 320. The media are presented in a folded configuration with two types of filter media mixed and stacked on top of each other. Filter media 310 and 320 are shown schematically without showing actual material ripples. The filter media stack 300 can typically be formed by rolling various types of media at the same time around a central axis. In a first exemplary embodiment, the surface area ratio of materials 310 to 320 is approximately 1: 1.

[0080] FIG. 4 is a schematic top view of an exemplary filter media stack 400 showing a rolled configuration with three types of filter media. The filter media stack 400 contains three types of filter media: first media 410, second media 420, and third media 430. The media are presented in a folded configuration with three types of filter media mixed and superimposed. Filter media 410, 420, and 430 are presented in schematic form without showing the actual flutes of these materials. The filter media stack 430 is typically formed by simultaneously rolling three different types of media around a central axis. In this exemplary embodiment, the ratio of the surface areas of materials 410 to 420 to 430 is approximately 1: 1: 1.

[0081] FIG. 5 is a schematic top view of an exemplary filter media stack 500 showing a stacked configuration with two types of grooves. The filter media package 500 contains two types of riffles: first riffles 510 and second riffles 520.

[0082] FIG. 6 is a schematic top view of an exemplary filter media stack 600 showing a stacked configuration with various types of filter media. The filter pack 600 contains three types of riffles: first riffles 610, second riffles 620 and third riffles 630.

[0083] FIG. 7 is a schematic top view of an exemplary filter media stack 700 showing a stacked configuration with various types of grooves. The filter media package 710 contains two types of reefers: the first 710 reefers and the second 720 reefers.

[0084] FIG. 8 is a schematic top view of an exemplary filter media stack 800 showing a stacked configuration with three types of filter media. The three types of filter media are the first 810, the second 820, and the third 830. The materials are shown in a stacked configuration with three types of filter media, not mixed, but separated by media type. In this exemplary embodiment, the ratio of the surface areas of the filter media 810 to 820 to 830 is approximately 4: 3: 3 based on the inlet area of the bag.

[0085] FIG. 9 is a schematic top view of an exemplary filter media stack 900 showing a stacked configuration with two types of filter media, a first fabric 910 and a second fabric 920. The materials are shown in a stacked configuration with separate rather than mixed filter media of the two types. In this exemplary embodiment, the ratio of the surface areas of the filter media 910 to 920 is approximately 1: 1 based on the total inlet area of the stack.

[0086] FIG. 10 is a schematic top view of an exemplary filter media stack 1000 showing a stacked configuration with two types of filter media: a first fabric 1010 and a second fabric 1020. The materials are presented in a stacked configuration. In this exemplary embodiment, the ratio of the surface areas of the filter media 1010 to 1020 is approximately 9: 1 based on the total inlet area of the stack.

[0087] FIG. 11 is a schematic top view of an exemplary filter media stack showing a stacked configuration with two types of filter media. The filter media package 1100 contains two types of filter media: first media 1110 and second media 1120. Media 1110 and 1120 are stacked with five layers of filter media 1110 alternating with two layers of media 1120.

[0088] FIG. 12 is a schematic top view of an exemplary filter media stack showing a stacked configuration with two types of filter media. The filter media stack 1200 contains two types of filter media: a first media 1210 and a second media 1220. The media are presented in a stacked configuration. Materials 1210 and 1220 are stacked with two layers of filter material 1210 alternating with one layer of material 1220.

[0089] FIG. 13 is a schematic top view of an exemplary filter media stack 1300 showing a stacked configuration with two types of filter media. The filter media package 1300 contains two types of filter media: first media 1310 and second media 1320. Media 1310 and 1320 are stacked with one layer of filter media 1310 alternating with one layer of media 1320.

[0090] FIG. 14 is a schematic top view of an exemplary filter media stack 1400. The filter media stack 1400 contains three types of filter media: first media 1410, second media 1420, and third media 1430. Layers of media 1410, 1420, and 1430 are stacked alternately.

[0091] FIG. 15 is a schematic top view of an exemplary filter media stack 1500 showing a rolled configuration with two types of filter media 1510 and 1520. These materials are folded so that the first material 1510 is on the inside and the second material 1520 is on the outside, while the first and second materials 1510, 1520 are spliced together.

[0092] FIG. 16 is a schematic top view of an exemplary filter media stack 1600 showing a rolled configuration with three types of filter media 1610, 1620, and 1630. These materials are folded so that the first material 1610 is on the inside, the second material 1620 is in the middle, and the third material 1630 is on the outside. The first and second materials 1610, 1620 are spliced together, as are the second and third materials 1620, 1630.

[0093] FIG. 17 is a schematic top view of an exemplary filter media stack 1700 showing a stacked configuration with three types of filter media. These three types of filter media are the first material 1710, the second material 1720, and the third material 1730. The materials are shown in a stacked configuration with three types of filter media, not mixed, but separated by media type. In this exemplary embodiment, the ratio of the surface areas of the filter media 1710 to 1720 to 1730 is approximately 4: 3: 3 based on the total inlet area of the stack.

[0094] FIG. 18 is a schematic top view of an exemplary filter media stack 1800 showing a stacked configuration with two types of filter media, a first fabric 1810 and a second fabric 1820. The material is presented in a stacked configuration with two types of separated filter media. In this exemplary embodiment, the ratio of the surface areas of the filter media 1810 to 1820 is approximately 1: 1 based on the total inlet area of the stack.

[0095] FIG. 19 is a schematic top view of an exemplary filter media stack 1900 showing a stacked configuration with two types of filter media. The filter media package 1900 contains two types of filter media: the first material 1910 and the second material 1920. The materials are presented in a stacked configuration. In this exemplary embodiment, the ratio of the surface areas of the filter media 1910 to 1920 is approximately 9: 1 based on the total inlet area of the stack.

[0096] FIG. 20 is a schematic top view of an exemplary filter media stack 2000 showing a stacked configuration with two types of filter media. The filter media package 2000 contains two types of filter media: the first 2010 media and the second 2020 media. The media bag 2000 contains six layers of 2010 filter media alternating with two 2020 media layers.

[0097] FIG. 21 is a schematic top view of an exemplary filter media stack 2100 showing a stacked configuration with two types of filter media. The filter media stack 2100 contains two types of filter media: the first material 2110 and the second material 2120. The media stack 2100 contains two layers of filter media 2110 alternating with one layer of media 2120.

[0098] FIG. 22 is a schematic top view of an exemplary filter media stack 2200 showing a stacked configuration with two types of filter media. The two types of filter media are the first material 2210 and the second material 2220. The material is presented in a stacked configuration with mixed filter media of the two types.

[0099] FIG. 23 is a schematic top view of an exemplary filter media stack 2300 showing a stacked configuration with three types of filter media. The three types of filter media are the first material 2310, the second material 2320, and the third material 2330. The materials are presented in a stacked configuration with three types of mixed filter materials.

[00100] FIG. 24A is a schematic top view of an exemplary filter media stack 2400 showing a folded configuration with two types of filter media: a first fabric 2410 and a second fabric 2420. The materials are presented in a folded configuration with two types of media differing from each other in that the filter media 2420 is stacked first. and filter media 2420 is stacked second. In this exemplary embodiment, the ratio of 2420 to 2410 cross-sectional areas at the entrance to the stack is approximately 2: 1. Such a structure can be created, for example, by rolling the first one-sided type material over a period of time, cutting the web and splicing the second one-sided type material with the end region of the first one-sided type material, continuing the folding process and repeating it for any required amount of one-sided type materials. Alternatively, the folding of each single sided type material can be done separately and the sections can be brought together and sealed as a secondary process.

[00101] FIG. 24B is a schematic top view of an exemplary filter media stack 2450 showing a folded configuration with filter media formed from two types of riffles. The filter media package 2540 contains two types of riffles, a first material 2460 and a second material 2470. The materials are presented in a folded configuration with two types of riffles separated from each other. In this exemplary embodiment, the ratio of 2470 to 2460 cross-sectional areas at the entrance to the stack is approximately 2: 1.

[00102] FIG. 25A is a schematic top view of an exemplary filter media stack 2500 showing a rolled configuration with three types of filter media: first media 2510, second media 2520, and third media 2530. The media are presented in a rolled configuration with media separated from each other by filter media 2520 stacked first, then second fabric 2520 stacked on top of fabric 2510, and third fabric 2530 stacked on top of fabric 2520. In this exemplary embodiment, the ratio of cross-sectional areas 2510 to 2520 to 2530 at the bag entrance is approximately 4: 3: 3.

[00103] FIG. 25B is a schematic top view of an exemplary filter media stack 2550 showing a folded configuration with three types of filter media. The filter media package 2550 contains a first material 2560, a second material 2670, and a third material 2680. The materials are presented in a folded configuration with three types of materials separated from each other. In this exemplary embodiment, the ratio of 2560 to 2570 to 2580 at the entrance to the stack is approximately 4: 3: 3.

[00104] FIG. 26A is a schematic top view of an exemplary filter media stack 2600 showing a rolled configuration with two types of filter media. The filter media package 2600 contains two types of filter media: a first material 2610 and a second material 2620. The media are presented in a folded configuration with two types of media separated from each other by having filter media 2620 stacked first and filter media 2620 stacked on top of the media. 2610. In this exemplary embodiment, the ratio of the cross-sectional areas 2610 to 2620 at the entrance to the stack is approximately 1: 1.

[00105] FIG. 26B is a schematic top view of an exemplary filter media stack 2650 showing a folded configuration with two types of filter media. The filter media package 2540 contains two types of filter media: a first material 2660 and a second material 2670. The materials are presented in a folded configuration with two types of materials separated from each other. In this exemplary embodiment, the ratio of 2660 to 2670 cross-sectional areas at the entrance to the stack is approximately 1: 1.

[00106] The aspects can be better understood by referring to the following example, which compares element A, element B and element C with each other. Element A consisted entirely of material A with corrugations having a width of approximately 10.7 mm and a height of 3.2 mm and wedge-shaped cross-sectional area. Element B consisted entirely of material B with grooves having a width of approximately 8.0 mm and a height of 2.7 mm and a wedge-shaped area. The density of the grooves per square centimeter was approximately 2.8 for element A and 4.4 for element B. Element C consisted of 50 vol. % of material A and 50 vol. % of material B forming a hybrid material. FIG. 27 shows the load curves for filter elements using material A, material B and hybrid material. These load curves represent the pressure loss for the filter elements as the dust mass increases from zero to less than 500 g. As shown in FIG. 27, the curves of material B and hybrid material start at very close confinement levels (about 2.5 inches of water), while material A has a larger initial pressure loss of about 3.2 inches of water. As dust begins to accumulate, the pressure loss in the cell increases, however, material A and hybrid material have a slower increase in pressure loss than material B, and the pressure loss curves for material A and material B intersect (or their pressure loss becomes equal) at approximately 125 g of dust. Thus, the curve of the hybrid material runs closer to the curve of material B at the very beginning of the dust load, and then, as the dust load increases to higher levels, it passes near the curve of material A. In other words, the hybrid material has an initial constraint similar to material B. but a load similar to material A.

[00107] To further determine the improved performance of the filter, a two-channel system with an air flow rate of 5-9 cubic meters per minute was installed on the test bench, configured to measure pressure loss and outlet limiting values. The relative performance of elements with materials formed using combinations of filter materials was investigated by creating various filter element structures. The elements were formed from zigzag materials arranged in a stacked configuration. Each element had an entrance surface of 150 by 150 millimeters, an exit surface of 150 by 150 millimeters, and a depth of 150 millimeters. The filter elements were made of two types of materials, material A and material B. Material A and material B had a corrugated material structure corresponding to the structure presented in US patent No. 9623362, entitled "Filtration Media Pack, Filter Elements, and Air Filtration Media" ( "Filter Media Package, Filter Elements and Air Filtration Media") issued to inventor Scott M. Brown and assigned to Donaldson Company, Inc. Both materials, material A and material B, were generally cellulose-based materials. Material A had a corrugation height of approximately 0.092 inches, a corrugation width of approximately 0.314 inches, and a corrugation length of approximately 150 mm (including the corrugation plugs). Material B had a corrugation height of approximately 0.140 inches, a corrugation width of approximately 0.430 inches, and a corrugation length of approximately 150 mm (including the corrugation plugs). The “segmented” stack of materials of the first type were combined stacks of material A and material B, located next to each other in a parallel flow configuration. The "layered" stack of materials of the second type contained alternating sheets of material A and material B.

[00108] FIG. 28A-30B show the results of performance tests, including dust loading and pressure loss, for materials of various structures. FIG. 28A, 29A and 30A show the results for a segmented configuration (material A is grouped and material B is grouped); and in FIG. 28B, 29B and 30B show the results for a layered configuration (in which at least some of the layers of material A and material B were mixed). Thus, the material structures include any of the materials: material A, material B, or different volume percentages of material A and material B. The material in each leftmost graph, denoted as 0%, does not contain material A and thus contains only material B The material on each right-most graph, labeled as 100%, contains only material A and thus does not contain material B. The Y-axis represents the ISO fine dust load and pressure loss, measured in inches of water.

[00109] FIG. 28A and 28B show the results of performance tests, including dust loading and pressure loss, for materials of various structures at a volumetric flow rate of 5.83 cubic meters per minute. FIG. 28A and 28B, it can be observed that the best performance, in particular the highest dust load, was achieved for the hybrid material: a hybrid material bag containing both material A and material B has a higher dust holding capacity than either material A or B. separately.

[00110] FIG. 29A and 29B show the results of performance tests, including dust loading and pressure loss, for materials of various structures at a volumetric flow rate of 7.37 cubic meters per minute. In the same way as in FIG. 29A and 29B, a hybrid material consisting of material A and material B had the best performance.

[00111] FIG. 30A and 30B show the results of performance tests, including dust loading and pressure loss, for materials of various structures at a volumetric flow rate of 8.78 cubic meters per minute. FIG. 30A and 30B, it can be observed that the best performance, in particular the highest dust load, was also achieved for the hybrid material.

[00112] It should be noted that in the context of the present technical description and the appended claims, singular references also include plural references, unless the context clearly indicates otherwise. Thus, for example, reference to a composition containing a "compound" includes a mixture of two or more compounds. It should also be noted that the term “or” is usually used in its own sense, including “and / or”, unless the context clearly indicates otherwise.

[00113] It should also be noted that in the context of the present technical description and the appended claims, the phrase "configured" describes a system, apparatus, or other structure constructed or configured to perform a specific task or to obtain a specific configuration for this purpose. The phrase "configured" may be interchangeable with other similar phrases such as positioned and configured, created and positioned, constructed, manufactured and positioned, and the like.

[00114] Aspects have been described with reference to various specific and preferred embodiments and technologies. However, it should be understood that many changes and modifications can be made without departing from the scope and spirit of the invention.

[00115] The embodiments described in this application should not be construed as being exhaustive or limiting the invention to the precise forms disclosed in the above detailed description. Rather, the embodiments are selected and described so that those skilled in the art can appreciate and understand the principles and their practical application.

[00116] All publications and patents mentioned in this application are incorporated by reference. The publications and patents disclosed in this application are presented for disclosure purposes only. Nothing in this application should be construed as an admission that the inventors are not entitled to retrodate any publication and / or patent cited in this application.

Claims (23)

1. Air filtration package containing: a one-sided material comprising a first plurality of corrugations and a second plurality of corrugations, the first and second pluralities of corrugations being arranged in a parallel flow configuration; wherein the first and second pluralities of corrugations are characterized by differences in corrugation shape, corrugation size, corrugation height, corrugation width, corrugation cross-sectional area, or filter material; and wherein the first plurality of corrugated material is located in the first plurality of corrugated layers in the stack of materials, and the second plurality of corrugated material is located in the second plurality of corrugated layers in the stack of materials. 2. The package of materials for filtering air according to claim. 1, characterized in that the first and second plurality of corrugated material are arranged together in at least one layer of corrugated material. 3. A package of materials for filtering air according to claim 1, characterized in that the first plurality of corrugations constitutes 10-90% of the volume of the package of materials, and the second set of corrugations constitutes 90-10% of the volume of the package of materials. 4. A package of materials for filtering air according to claim 1, characterized in that the first set of corrugations is 20-40% of the volume of the package of materials, and the second set of corrugations is 60-80% of the volume of the package of materials. 5. A package of materials for filtering air according to claim 1, characterized in that the first plurality of corrugations makes up 40-60% of the volume of the package of materials, and the second set of corrugations makes up 60-40% of the volume of the package of materials. 6. The package of materials for filtering air according to claim. 1, characterized in that the first plurality of corrugations is 10-90% of the surface area of the materials of the package of materials, and the second set of corrugations is 90-10% of the surface area of the materials of the package of materials. 7. The package of materials for filtering air according to claim. 1, characterized in that the first plurality of corrugations is 20-40% of the surface area of the materials of the package of materials, and the second set of corrugations is 60-80% of the surface area of the materials of the package of materials. 8. The package of materials for filtering air according to claim 1, characterized in that the first plurality of corrugations is 40-60% of the surface area of the materials of the package of materials, and the second set of corrugations is 60-40% of the surface area of the materials of the package of materials. 9. The package of materials for filtering air according to claim 1, characterized in that the first plurality of corrugations constitutes 10-90% of the entrance surface of the package of materials, and the second plurality of corrugations constitutes 90-10% of the entrance surface of the package of materials. 10. The package of materials for filtering air according to claim 1, characterized in that the first plurality of corrugations constitutes 20-40% of the entrance surface of the package of materials, and the second plurality of corrugations constitutes 60-80% of the entrance surface of the package of materials. 11. The package of materials for filtering air according to claim 1, characterized in that the first plurality of corrugations constitutes 40-60% of the entrance surface of the package of materials, and the second plurality of corrugations constitutes 60-40% of the entrance surface of the package of materials. 12. The air filtration package of claim 1, wherein the first plurality of corrugated layers and the second plurality of corrugated layers are arranged in a mixed configuration with one or more layers of the first plurality of layers alternating with one or more layers of the second plurality of layers. 13. The package of materials for filtering air according to claim 1, characterized in that it further comprises a third plurality of corrugations arranged in a parallel flow configuration with the first and second plurality of corrugations; wherein the first, second, and third pluralities of corrugations are characterized by differences in corrugation shape, corrugation size, corrugation height, corrugation width, corrugation cross-sectional area, or filter material. 14. The package of materials for filtering air according to claim. 13, characterized in that each of the first, second and third plurality of corrugations is located in a separate plurality of layers. 15. The package of materials for filtering air according to claim 13, characterized in that the first, second and third pluralities of corrugations are arranged in a mixed configuration with one or more pluralities of layers alternating with other pluralities of layers. 16. The package of materials for filtering air according to claim. 1, characterized in that the plurality of layers of materials are arranged in a folded configuration. 17. The package of materials for filtering air according to claim 1, characterized in that the differences in the shape of the corrugation, the size of the corrugation, the height of the corrugation, the width of the corrugation, the cross-sectional area of the corrugation or the filter material are regular and repetitive. 18. A filter element or air cleaner containing a package of materials for filtration according to claim 1. 19. A method for filtering a fluid stream, which includes passing the fluid stream through a filter element according to claim 18.

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